Headlight to Body Alignment

[Cleet H.]

I recently disassembled my headlights to restore them and am having an extra difficult time getting the doors to align with the body. I have searched the archives for suggestions and gone through the steps in the service manual, but I always end up with one corner way off (1/8 - 1/4 inch too high or too low). Should I try using shims on the supports or is it possible that the body is twisted slightly since it is not on the frame? I'll try anything at this point.

[Rich P.]

Re: Headlight to Body Alignment

Cleet,

Several things to try here. FIRST DON'T BE AFRAID TO TWIST THE DOOR IT SELF. This works for the leading edges of the door, if one side is up and the other down. If the car is already painted I would do this carefully but it can be done. If the car has not been painted yet then crank away.
Second. I have had to place paint sticks under the edges of the doors and press the door down on the surround and carefully hammer the high spots on the door to make them fit flush. (Again be careful as the doors are pot metal and can crack. But I have done this countless times with no cracks just use a body hammer not a sledge!!!)
Third sometimes it is necessary to ream out the hoes for the headlight bearing bolts and center hole. When the bearings are replaced you don't always get the same amount of adjustment out of the the bearing to actuator support.
These are just a few to help you start. Let me know how it helps and I can give more suggestion if needed.

Rich

I forgot to add that the car not sitting on the frame should not greatly affect that as long as it is supported properly.

[Cleet H.]

Re: Headlight to Body Alignment

Paint is not a problem. I was planning to have the headlight doors repainted due to pitting anyway then I knocked a chip of paint off the car the size of a quarter during my first attempt to reinstall - so it looks like I'll be painting the entire nose? Therefore twisting sounds like a great idea, I just didn't know that was an option. In case that doesn't work what is a paint stick?
Thanks for the suggestions - will let you know how it goes this evening.

[Rich P.]

Re: Headlight to Body Alignment

Cleet,

a paint stick is just a thin piece of wood that you get with a gallon of paint for mixing. Sorry thats a body shop term.
Another thing to do is to put the paint stick/block of wood between the surround and door (on the low side) then push down on the other side to help in the twist.

Rich